Machine for winding and inserting coils

ABSTRACT

In a machine for winding and inserting coils of the type wherein a flier is rotated so as to wind the conductor drawn from the flier around two blades of an insertion tooling and an auxiliary plate located radially outwardly of said two blades and spaced apart therefrom by a predetermined distance, thereby forming a coil which is directly inserted together with a wedge into slots of a magnetic core of a rotary electric machine, an improvement wherein the blades with wedge guides which form the insertion tooling are divided into alternating main and auxiliary blades equiangularly spaced apart from each other, the auxiliary blades being axially movable relative to said main blades in such a way that when the conductor is wound around a bobbin formed by two of the main blades and an auxiliary plate, the auxiliary blades are retracted away from the main blades, but when the wound coils are inserted into the slots of the magnetic core, the auxiliary blades are raised to align with the main blades, thus forming the insertion tooling. In addition, all the coils for one phase may be continuously wound so as to have only one starting lead and one finishing lead.

BACKGROUND OF THE INVENTION

The present invention relates to generally a machine for winding coilsand inserting the same into the slots of a magnetic core of a rotaryelectric machine and more particularly a machine for winding coils andinserting the same along with wedges into the slots of a magnetic coreof a rotary electric machine.

The assembly of magnetic cores such as stators of rotary electricmachines includes a step of inserting into the slots of a stator thecoils which have been previously wound and a step of inserting thewedges into the slots.

It has been well known in the art that especially when the coilsconsisting of many turns of a fine conductor are inserted into thestator core of a motor, it is by far preferable to insert both the coilsand wedges simultaneously than separately because better performance orqualities of the coils may be maintained; that is, the disconnection ofthe coil may be minimized; the degradation of the insulation due to thedamage to the conductor may be prevented; and the coils may be securelyheld in the slots by the wedges.

There has been devised and demonstrated a machine capable ofsimultaneously inserting all the coils and wedges into a stator core.This machine is provided with a plurality of blades which are extendedthrough a stator core and contact the inside peripheral surface thereofso as to guide the coils towards the slots and a plurality of wedgeguides which contact with one of the end faces of the stator core so asto guide the wedges towards the slots. The coils to be inserted arepreviously wound by a separate winding machine and are inserted betweenthe blades according to a predetermined pattern. Thereafter they areinserted into the slots along with the wedges in the manner describedabove.

However the coil and wedge inserting machine of the type described abovehas some defects to be described below. When the edgewise wound coil isremoved from the bobbin of the winding machine and inserted into theinsertion tooling of the coil insertion machine, the coil is disturbedso that when the coil is inserted into the slots, the conductor of thecoil is trapped between the stator core and an inserting means and iscut off and the coil cannot be snugly inserted into the slots andsecurely held by the wedge, thus resulting in the rejection of thefinished product. In addition, manual labor is needed to remove the coilfrom the bobbin and mount it on the insertion tooling. Furthermore, theproductivity is low because the connections between the crossover leadsare needed after the insertion.

As disclosed for instance in U.S. Pat. No. 2,934,099, there has beeninvented and used a machine capable of winding a coil and directlyinserting it into the slots of a stator core. With this machine, thecoils for respective poles are formed individually around bobbins. As aresult, the simultaneous insertion of the coils and wedges isimpossible. In addition, after the coils and wedges are inserted, theconnection between the crossover leads is needed. Furthermore thewinding step and the insertion step must be alternately carried out forrespective poles. Thus, this machine has a low productivity and a lowrate of operation.

As disclosed for instance in U.S. Pat. No. 3,817,295, there has beenalso invented and used a machine wherein there is provided an insertertooling consisting of a plurality of blades with different heights andsupporting means disposed radially outwardly of the inserter tooling;and a coil is wound around a bobbin formed by two of the blades and oneof the supporting means, the wound coil being directly inserted into theslots of a stator core.

The last mentioned machine of the type described above has also a lowproductivity or a low efficiency because of the following reasons.Firstly, each time a coil for one pole is formed, it must be immediatelyinserted into the stator. As a result, many insertion steps are needed.In addition, the connection between the crossover leads is still needed.Furthermore since the blades are not uniform in height, the wound coilsare increased in length.

SUMMARY OF THE INVENTION

The present invention was made to overcome substantially the above andother problems encountered in the prior art machines for winding thecoils and inserting them into the slots of a stator core or the like andhas for its primary object the providing of a machine for winding andinserting coils which is capable of forming all the coils for one phasewithout disconnecting them between the poles and of inserting all thecoils and wedges simultaneously into the slots of a stator core or thelike.

According to one aspect of the present invention, the blades, whichconstitute an inserter or insertion tooling, are divided intoalternating main and auxiliary blades which are equiangularly spacedapart form each other. The auxiliary blades are so arranged so as to beaxially movable relative to the main blades. A plurality of auxiliaryplates are disposed radially outwardly of the insertion tooling andspaced apart therefrom by a suitable distance. When the coil is formedaround a bobbin which is formed by two of the main blades and one of theauxiliary plates, the auxiliary blades are retracted away from the mainblades or from the path of a flier. The flier is so rotated and a coilwinding head which carries the insertion tooling is so indexed that allthe coils for one phase are wound continuously without disconnectingthem between the poles. When all the coils to be inserted into the slotsof a stator core or the like are completed in the manner describedabove, the auxiliary blades are advanced to align with the main blades,thus forming the insertion tooling. The insertion tooling pushes thecoils along with the wedges supplied from a wedge supply means into theslots of the stator core or the like. Thus both the coils and wedges maybe inserted by a single insertion step. In addition, the need forinterconnecting the crossover leads between the coils for respectivepoles may be eliminated. As a consequence, the present invention mayconsiderably improve the productivity.

The above and other objects, features, effects and advantages of thepresent invention will become more apparent from the followingdescription of one preferred embodiment thereof taken in conjunctionwith the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view, partly broken, of a preferred embodimentof a machine for winding and inserting coils in accordance with thepresent invention;

FIG. 2 is a top view of a coil winding head thereof;

FIG. 3 is a sectional view taken along the line III--III of FIG. 2;

FIG. 4 is a view used for the explanation of the coil winding step;

FIG. 5 is a front view, partly in section, of a drive or index means;

FIG. 6 is a front view, partly in section, of a winding means;

FIG. 7 is a front view, partly in section, of a holding means;

FIG. 8 is a front view, partly in section, of an insertion means;

FIG. 9 is a side view, partly in section, of a wedge supply means;

FIG. 10 is a top view, partly broken, thereof, and

FIG. 11 is a side view of a handling means.

DESCRIPTION OF THE PREFERRED EMBODIMENT

A machine for winding and inserting coils in accordance with the presentinvention comprises in general, as shown in FIG. 1, a transfer meanscomprising a stand 12, securely mounted on a base 11, a vertical shaft15, drivingly coupled through a reduction gear 14 to a motor 13, mountedon the lower platform or deck of the stand 12 and extended upwardsthrough the upper platform or deck of the stand 12, and a turntable 16carried by the vertical shaft 15 at the upper end thereof for rotationin unison therewith. Four coil winding heads B are rotatably mounted onthe turntable 16 and are equiangularly spaced apart from each other aswill be described in more detail below. A drive or index means C ismounted on the upper deck of the stand 12 in opposed relationship withthe coil winding head B for indexing and positioning the same. Therewinding means D, D' and D" (only one D being shown for the sake ofsimplicity because the construction is similar) are mounted on frames17, 17' and 17", respectively, which, in turn, are mounted on the base11, in opposed relationship with the coil winding heads B which areindexed so as to wind a conductor into a coil. A stator core holdingmeans E is mounted on a frame or the like 18 in upwardly opposedrelationship with the coil insertion position for holding a stator coreso as to fit the same with the blades of the coil winding head B whichcarries all finished or wound coils and is brought to the coil insertionposition. An insertion means F for inserting the coils into the statorcore is held by the stator core holding means E. The insertion means Fis mounted on a stand 19 (which in turn is securely mounted on the base11) just below the insertion position. A wedge supply means G isarranged so as to supply the wedges to the insertion means F as will bedescribed in more detail with particular reference to FIGS. 9 and 10below. Conductor handling means H are provided for threading the end ofthe conductor drawn from the winding means D (D' and D") along apredetermined path and firmly holding it as will be described in detailhereinafter with particular reference to FIG. 11.

Coil Winding Head B, FIGS. 2, 3 and 4

The coil winding head B includes a disk-shaped base or index plate 21 ismounted on the turntable 16 for rotation and has an index gear 20securely attached to the undersurface thereof. A hollow cylindricalblade guide 23 is extended upwards coaxially of the base or index plate21 has a plurality of axial guide grooves formed in the inside wallthereof, projections 22 being extended from the guide grooves. Aplurality of supports 25 each having a projection 24 extended from theupper end thereof are arranged along the circumference of the hole ofthe blade guide 23 and equiangularly spaced apart from each other like acomb. A plurality of first wedge guides 26, each having a projection 26'extended from the upper end thereof for engagement with the projection24 of the support 25, are slidably fitted into the guide grooves of theblade guide 23. A plurality of main blades 28 have their lower endssecurely anchored to a cylindrical holder 27 having a plurality ofequiangularly spaced apart axial grooves which are formed in the outercylindrical surface of the holder 27 and adapted to cooperate with theguide grooves of the blade guide 23. A plurality of second wedge guides29, each having a projection 29' extended from the upper end thereof forengagement with the projection 22, are slidably fitted into the guidegrooves of the blade guide 23. A plurality of auxiliary blades 31,formed integral with the second wedge guides 29, have their lower endssecurely anchored to cylindrical holder 30.

Four equiangularly spaced apart blocks 32 are mounted on the base orindex plate 21 around the blade guide 23. An L-shaped auxiliary plate 35is pivoted with pins 33 to the block 32 and biased under the force of aspring 34 in one direction. Four, equiangularly spaced apart guideblocks 37 are also securely mounted on the base or index plate 21 aroundthe blade guide 23 and between the blocks 32. A sliding block 38,slidably fitted into a radial guide groove 36 formed in the uppersurface of the guide block 37, is normally biased in the radiallyoutward direction. A second auxiliary plate 41, also L-shaped, ispivoted with pins 39 to the block 38 and is biased to swing in onedirection.

As best shown in FIG. 2, a ring-shaped holder 43 is extended over thehorizontal branch or arm of each L-shaped first auxiliary plate 35 onthe block 32 and through circumferential grooves 36' of the guide blocks37. The holder 43 carries four arms 42 each of which is extended acrossand spaced apart upwardly by a suitable distance from the horizontalbranch of the L-shaped second auxiliary plate 41 as best shown in FIG.3. A plurality of pins 45 each with a head at the lower end thereof areextended downwards from the ring-shaped holder 43 through the indexplate 21 and the guide blocks 37 and are equiangularly spaced apart fromeach other as best shown in FIG. 2. A spring 44 is loaded between thehead of the pin 45 and the index base 11 so that the ring-shaped holder43 may be normally biased towards the index base.

Mounted on the upper cylindrical holder 27 is a coil insertion block 46which may slidably fit with both the main and auxiliary blades 28 and31. Mounted on the index plate 21 are conductor clamping means 47 eachconsisting of a pair of leaf springs for holding the end of the coil.Mounted on the frame 17' is a cylinder 47' which is adapted to push theblock 38 radially inwardly toward the blade guide 23 as will bedescribed in more detail below.

Next the mode of operation of the coil winding head B with the aboveconstruction will be described. As best shown in FIG. 4, each bobbin isformed with two main blades 28 and one auxiliary plate 35 or 41 and aflier 73 (which will be described in detail hereinafter with particularreference to FIG. 6) winds the coil 4 around the bobbin. When the firstauxiliary plate 35 is used, the second auxiliary plate 41 is held in theinoperative position which is indicated by the solid line and is out ofthe circular path of the flier 73.

When the second auxiliary plate 41 is to be used, the cylinder 47' isactuated to push the auxiliary plate 41 to the operative positionindicated by the one-dot chain line in FIG. 4. In this case theauxiliary blades 31 are held in the lowered or inoperative position sothat the passages for the flier 73 may be defined between the mainblades 28.

When the coil 4 is to be inserted into the stator core, the auxiliaryblades 31 are moved upwards to the same height as the main blades 28,thereby forming an insertion tooling.

Referring back to FIG. 3, when the pins 45 are pushed upwards bycylinders 141 (to be described in detail with particular reference toFIG. 8) so that the ring-shaped holder 43 and its arms 42 are moved awayfrom the horizontal branches or arms of the first and second auxiliaryplates 35 and 41, the latter are caused to swing towards the blade guide23 under the forces of the springs 34 and 40 so that the removal of thecoil 4 from the bobbin may be facilitated.

Drive or Index Means, FIG. 5

Referring to FIG. 5, the drive or index means C will be described indetail below. An index gear 51, rotatably mounted on the undersurface ofthe turntable 16 with a shaft 48 and bearings 49, is in mesh with theindex gear 20 carried by the coil winding head B. The gear 51 has aplurality of equiangularly spaced apart bushings 50 extended through thegear 51 in parallel with the axis thereof.

A housing 53 is mounted on frames 52 which, in turn, are securelymounted on the upper deck of the stand 12. A shaft 55 which isinternally splined and carries a pinion 54 at the lower end thereof isrotatably mounted on the housing 53. An externally splined shaft 56which is extended through the internally splined shaft 55 has an indexplate 58 carried at the upper end thereof coaxially of the index gear51. A plurality of equiangularly spaced apart engaging or index pins 57are extended upwards from the index plate 58 for engagement with thebushings 50 of the index gear 51. The lower end of the externallysplined shaft 56 is joined to the piston rod of a cylinder 59 which ismounted on the frame 52 so that the engaging pins 57 may engaged withand disengage from the bushings 50 of the index gear 51.

The pinion 54, carried by the internally splined shaft 55, is in meshwith a rack 62 slidably carried by a guide rail 60 securely attached tothe frame 52 and drivingly coupled to a cylinder 61.

The mode of operation of the drive or index means C is as follows. Whenthe coil winding head B is brought to the coil winding position as theturntable 16 rotates, the cylinder 59 is actuated so as to lift theexternally splined shaft 56, whereby the engaging or index pins 57 areinserted into the bushings 50 of the index gear 51. Next the cylinder 61is actuated to slide the rack 62 so that the pinion 54, in mesh with therack 62, is caused to rotate and consequently the externally splinedshaft 56, splined to the internally splined shaft 55 is caused torotate. As a result, the index gear 51, connected through the pin andbushing engagement with the externally splined shaft 56, is caused torotate, turning the mating index gear 20 of the coil winding head B,whereby the latter is indexed.

When the piston rod of the cylinder 59 is extracted or withdrawn, theexternally splined shaft 56 is lowered, whereby the pins 57 aredisengaged from the bushings 50 of the index gear 51. Thereafter thecylinder 61 is actuated to withdraw the rack 62 towards its initialposition. Then the index plate 58 is returned to its initial position.

Winding Means D, FIG. 6

Next referring to FIG. 6, the winding means D will be described in moredetail. Supports 65 and 66 are securely attached to the frame 17 and arespaced apart vertically by a suitably distance. An internally splinedshaft 69 is rotatably supported by bearings 68 mounted on a housing orbearing block 67 which, in turn, is securely mounted on the uppersupport 65. A hollow shaft 72, which has an externally splined upperportion 71 for engagement with the internally splined shaft 69, issupported not only by a bearing 70 which, in turn, is mounted securelyon the lower support deck 66 but also a bearing and carries the flier 73at the lower end thereof. A cylindrical slider 76 which is slidablyfitted over the hollow shaft 72 between the upper and lower supportdecks 65 and 66 is guide for vertical movement by an upright guide post75 extended vertically from the lower support deck 66.

A motor 71 is mounted on the bracket 78 joined to the frame 17 and has apulley 79 attached to the drive shaft thereof is drivingly coupled withan endless belt 80 to a pulley 77 splined to the externally splinedupper portion 71 of the hollow shaft 72. Therefore, upon rotation of themotor 71, the hollow shaft 72 and hence the flier 73 are turned.

Another motor 84 is mounted on the frame 17 with a bracket 82 and has apulley 83 attached to the drive shaft thereof and is drivingly coupledthrough an endless belt 86 to a pulley 85 carried by the input shaft ofa reduction gear 87 mounted on the frame 17. The output shaft of thereduction gear 87 is drivingly coupled through a coupling 89 to one endof a cam shaft 90 rotatably supported by a bearing 88 which, in turn, ismounted on the frame 17. The other end of the cam shaft 90 carries a camplate 93 with a cam groove 92 for engagement with a cam pin 91 extendedfrom the slider 76.

In order to synchronize the drive of both the motors 81 and 84, thelatter are equipped with sensors 94 and 95, respectively.

Both the hollow shaft 72 and the flier 73 are provided with guiderollers 96 for guiding the conductor 3 without causing any damagethereto.

Next the mode of operation of the winding means D will be described.When the coil winding head B is brought to the winding position andindexed in the manner described elsewhere and the main blades 28 and thefirst or second auxiliary plate 35 or 41 form a bobbin, both the motors81 and 84 are driven in synchronism with each other so that the hollowwinding shaft 72 is rotated while being moved upwards and downwards,whereby the edgewise wound coil 4 may be formed.

Stator Core Holding Means E, FIG. 7

Referring to FIG. 7, the stator core holding means E includes a base 101supported by a horizontal yoke or arms extended from the upper ends ofthe posts or the like 18 (See FIG. 1). Four guide rods 102 which aredepending from the base 101 have their lower ends securely joined to asupporting plate 106 with a center aperture 103 through which areinserted the coils 4 and positioning pins 105. A pallet 104 whichreceives the stator core 7 is mounted on the supporting plate 106 andpositioned correctly with its positioning or reference holes fitted overthe positioning pins 105 of the supporting plate 106.

A holding plate 110 is slidably fitted over the guide rods 102 and isconnected to the piston rod of a cylinder 107 depending from the base101 so that, as the cylinder 107 is actuated, the holding plate 110 ismoved upwards away from the supporting plate 106 or downwards toward theplate 106 along the guide rods 102. A hollow cylindrical projection 109with a through bore 108 is extended downwards from the holding plate 110in the coaxial relationship with the stator core 7 received by thepallet 104 in such a way that the cylindrical projection 109 maysecurely hold down the stator core 7 when the coils 4 are insertedtherein as will be described in more detail hereinafter.

A movable base or plate 114 is guided by a guide bar or rod 111 extendedupright from the holding plate 110 and through the base 101 and isjoined to the piston rod of a cylinder 112 depending from the base 101so that the movable plate or base 114 may be moved vertically along theguide rod 111 as the cylinder 112 is extended or withdrawn. A tubular orelongated cylindrical projection 113, depending from the movable plateor base 114, is extended through the cylindrical projection 109 of theholding plate 110. A plurality of equiangularly spaced, axial fin-likeprojections 113' are extended radially outwardly from the lower portionof the cylindrical projection 113. A cylinder 116 is mounted on themovable plate or base 114 in such a way that its piston rod 115 mayextend through the tubular or elongated cylindrical projection 113.

The mode of operation of the holding means E is as follows. When thecoils 4 are inserted into the stator core 7 from the coil winding headB, the stator core 7 is supported or received by the pallet 104 which,in turn, is mounted on the supporting plate 106 with the positioningpins 105 inserted into the mating positioning holes of the pallet 104.Thereafter the cylinder 107 is actuated to lower the holding plate 110to such a position where the lower end of the cylindrical projection 109may be spaced apart from the stator core 7 by a predetermined distance.Next the cylinder 112 is actuated to lower the movable base 114 so thatthe projection 113 may extend through the stator core 7. In this case,the fin-like projections 113' of the projection 113 engage with theslots of the stator core 7 so that the latter may be accuratelypositioned in both the horizontal and circumferential directions. Underthese conditions, a port of the cylinder 112 which has been communicatedwith a source (not shown) of pressurized air is opened to thesurrounding atmosphere so that its piston rod may move freely. Next thecoils 4 and the wedges are simultaneously inserted into the stator core7 from the below by the insertion means F to be described in detailhereinafter. The projection 113 is pushed upwards by the insertion block46 of the coil winding head B which, in turn, is pushed upwards by theinsertion means F so that the projection 113 is moved away from thestator core 7. After the coils and wedges have been inserted into thestator core 7, the cylinder 116 is actuated to extend the rod 116 so asto push the insertion block 46 away from the stator core 7, whereby boththe main and auxiliary blades 28 and 31 are forced to move away from thestator core 7. Thereafter the cylinders 107, 112 and 116 are actuated soas to return the supporting plate 106, the movable base 114 and the rod115 to their initial positions, whereby the pallet 104 may be removedfrom the supporting plate 106.

Insertion Means F, FIGS. 1 and 8

Referring to FIGS. 1 and 8, extended between the top plate of the stand19 and a sub-base 120 securely mounted on the base 11 are a plurality ofguide rods or bars 121 and 122 and a plurality of lead screws 123, 124and 125. A lift plate 129 has upright sleeves 126 slidably fitted overthe guide rods 121 and a nut 127 engaged with the lead screw 123 so thatas the lead screw 123 is rotated, the lift plate 129 is moved upwardsalong the guide rods or bars 121. A hollow shaft 128, whose base issecurely joined to the upper surface of the lift plate 129, is extendedthrough the wedge supply means G (to be described in detail hereinafter)with the upper end of the hollow shaft 128 in opposed and coaxialrelationship with the lower cylindrical holder 30 of the coil windinghead B.

An insertion plate 134 has sleeves 130 slidably fitted over the guiderods or bars 121 and nuts 131 in engagement with the lead screws 124 sothat the insertion plate 134 may be vertically moved along the guiderods or bars 121 as the lead screws 124 are rotated. A shaft 132, whoselower end is securely anchored to the insertion plate 134, is extendedthrough the hollow shaft 128. A plurality of equiangularly mutuallyspaced wedge insertion blades 133 are extended upwards from theinsertion plate 134 and are spaced apart radially outwardly by apredetermined distance from the shaft 128. The wedge insertion blades133 extend slidably through both the lift plate 129 and the wedge supplymeans G so as to insert into the slots of the stator core 7 the wedgesformed by the wedge supply means G as will be described in more detailhereinafter.

Referring particularly to FIG. 1, a reversible motor 136 is mounted on abracket 135 which, in turn, is mounted on the sub-base 120 and isdrivingly coupled to electromagnetic clutches 137, 138 and 139 carriedat the lower ends of the lead screws 123, 124 and 125, respectively,through the belt drives including endless belts 140.

A plurality of cylinders 141 are mounted on the deck of the stand 19 inopposed relationship with the pins 45 of the coil winding head B (Seealso FIG. 3).

The mode of operation is as follows. In order to insert the coils 4 intothe stator core 7, the motor 136 is rotated in one direction whileelectromagnetic clutches 137, 138 and 139 are engaged or energized sothat the lead screws 123, 124 and 125 are rotated, whereby both the liftplate 129 and the insertion plate 134 are lifted, the wedge supply meansG being also lifted as will be described in detail hereinafter. Thewedge supply means G pushes the lower cylindrical holder 30 of the coilwinding head B, thereby causing the auxiliary blades 31 to lift to thesame height as the main blades 28 so as to form the insertion tooling asdescribed elsewhere. Simultaneously the cylinders 141 are actuated topush the pins 45 upwards so that the ring-shaped holder 43 may be liftedaway from the first and second auxiliary plates 35 and 41. As a result,they are caused to incline toward the insertion tooling 28 and 31 asdescribed elsewhere under the forces of the bias springs 34 and 40,whereby the removal of the coils from the bobbins may be facilitated.Thereafter the electromagnetic clutches 137 and 139 are de-energized ordisengaged so that only the insertion plate 134 may be permitted to movefurther upwards and push the wedges away from the wedge supply means Gso as to insert them into the wedge guides 26 and 29 between the mainand auxiliary blades 28 and 31 (See also FIG. 4). Next theelectromagnetic clutch 137 is energized or engaged again so that thelift plate 129 is lifted again in unison with the insertion plate 134and the upper ends of the main and auxiliary blades 28 and 31 areextended through the stator core 7. When the wedge guides 26 and 29engage with the lower end of the stator core 7, the electromagneticclutch 137 is de-energized or disengaged again. As a result, only theinsertion plate 134 is further lifted so that the hollow shaft 132 andthe wedge guide blades 133 are moved upwards. The hollow shaft 132pushes the insertion block 46 upwardly which, in turn, pushes upwardsthe coils 4 along the main and auxiliary blades 28 and 31 into the slotsof the stator core 7. Simultaneously, the blades 133 push the wedgesalong the blade guides 26 and 29 into the slots of the stator core 7.

After the coils and wedges have been inserted into the stator core 7 inthe manner described above, the motor 136 is reversed so that the leadscrews 123, 124 and 125 are rotated in the opposite direction andconsequently the insertion plate 134 along with the hollow shaft 132 andwedge guide blades 133 is lowered. Next the electromagnetic clutch 137is actuated so as to cause the lift plate 129 to move downwards alongwith the shaft 128. Concurrently the cylinder 116 (See FIG. 7) of theholding means E is actuated to extend its rod 115, thereby pushing theinsertion block 46 downwards. As a result, the insertion tooling or themain and auxiliary blades 28 and 31 are moved away from the stator core7. Next the electromagnetic clutch 139 is actuated so as to lower thewedge supply means G. When the lift plate 129, the insertion plate 134and the wedge supply means G are returned to their initial positions,respectively, the electromagnetic clutches 137, 138 and 139 arede-energized or disengaged and then the motor 136 is stopped.

Wedge Supply Means G, FIGS. 9 and 10

Referring to FIGS. 9 and 10, the wedge supply means G includes a movablebase 147 with the sleeves 145 slidably fitted over the guide rods orbars 122 and the nuts 146 engaged with the lead screws 125 so that themovable base 147 may be raised or lowered as described briefly inconjunction with the insertion means F. A pair of columns or the like148 are erected upright on the movable base 147 and are spaced apartfrom each other by a suitable distance in the horizontal direction andan L-shaped base 149 is mounted on the columns or the like 148. Sideplates 150 are mounted on the base 149 and spaced apart from each otherby a suitable distance (See FIG. 10).

A motor 152 which is mounted on one of the side plates 150 has its driveshaft 151 extended through both the side plates 150 as best shown inFIG. 10. The drive shaft 151 carries not only a cam plate 153 which ispositioned between the side plates 150 but also another cam plate 17 anda disk 176, both of which are located beyond the other side plate 150 asbest shown in FIG. 10.

A hoop supply reel 191 is rotatably carried by a bracket 190 dependingfrom the movable base 147 as best shown in FIG. 9 and a hoop guideroller 192 is rotatably carried by a bracket 193 depending from thelower end of the vertical portion of the L-shaped base 149 in order toguide the hoop 4", unwound from the supply reel 191, into a verticalguide passage extended through the vertical portion of the L-shaped base149.

A vertically elongated guide groove 181' is formed through the verticalportion of the L-shaped base 149 in parallel with the passage of thehoop 4" as best shown in FIG. 9, and a hoop feed block 184 with an arm182 is slidably fitted into the guide groove 181'.

The upper end of a link or crank 180 is pivoted with a pin to a block178 mounted on a base 177' which, in turn, is securely attached to thedisk 176. An adjusting screw 177 is provided between the block 178 andthe base 177' so that the eccentricity of the block 178 may be adjustedas is well known in the art. The other end of the link or crank 180 ispivoted with a pin to a link or a coupler 181 at a point substantiallyintermediate of its ends and one end of the link or coupler 181 ispivoted with a pin to the lower end of a supporting bar or the like 179depending from a side plate 163 attached to the side plates 150 whilethe other end of the coupler 181 is pivoted with a pin to one end of alink or lever 183 with the other end pivoted with a pin to the hoop feedblock 184. Therefore, as the disk 176 is rotated, the hoop feed block184 is vertically reciprocated in the guide groove 181' as is well knownto those skilled in the art.

A pawl 187 is pivoted to the block 184 and is biased under the force ofa spring 185, and a stopper 186 is attached to the block 184 in order tolimit the angle of rotation of the pawl 187. When the block 184 israised, the pawl 187 engages with the hoop 4", thereby lifting the same,but when the block 184 is lowered, the pawl 187 is released from thehoop 4". Another pawl 189 is pivoted to a block 188 attached to theL-shaped base 149 adjacent to the bend thereof and is extended into thepassage of the hoop 4" in such a way that the pawl 189 may permit thelift of the hoop 4" but may prevent the free fall thereof by engagingtherewith.

A holder 158 upon which is mounted a stationary blade 159 is securelyinterposed between the side plates 150 and a wedge magazine 169 with aplurality of equiangularly spaced axial grooves 168 for receiving thewedges 4' therein is rotatably mounted on the holder 158. A ratchetwheel 167 is mounted on the magazine 169 coaxially thereof.

A reciprocating rod 175, guided by a guide 171 attached to the sideplate 150, carries at one end a cam follower or roller 172 whichcontacts the cam disk 170. The rod 175 has a pawl or catch 173 pivotedat the other end thereof for engagement with the teeth 167' of theratchet wheel 167 as best shown in FIG. 10. As the rod 175 is displacedto the left in FIG. 10, the catch 173, biased under the force of a leafspring 174 against the ratchet wheel 167, engages with the tooth 167'and pulls the same, thus causing the ratchet wheel 167 and hence themagazine 169 through an angle corresponding to the pitch of the grooves168 thereof.

An L-shaped slider 162 is slidably mounted on the L-shaped base 149 andcarries a roller 160 rotatably attached to the upper end of the uprightportion which contacts the cam plate 153 under the force of a biasspring 165 loaded between the slider 162 and the end plate 163 on a bolt164 which is slidably extended through the side plate 163. The slider162 further carries a movable blade 161 attached to the other end remotefrom one end from which is extended the bolt 164, the movable blade 161coacting with the stationary blade 159 so as to cut a wedge 4' off fromthe hoop 4". Another reciprocating rod 157 which is slidably guided by aguide block 154, securely interposed between the side plates 150, has apusher 156 attached to one end thereof for pushing the wedge 4' into thegroove 168 of the magazine 169 and a cam follower or roller 155rotatably carried at the other end thereof and made into contact withthe cam disk 153.

A top plate or cover 166 is mounted on the side plates 150 and theholder 158 and supports the upper end of the shaft of the ratchet wheel167.

The mode of operation of the wedge supply means G is as follows. Beforethe wedge guide blades 133 of the insertion means G are raised in themanner described elsewhere, the motor 152 is rotated so that the disk176 is rotated so as to swing the link or coupler 181. As a result, thehoop feed block 184 is caused to move upwards, lifting the hoop 4" by apredetermined length in the manner described elsewhere. Thereafter theslider 162 is reciprocated by the rotation of the cam disk 153 so thatthe stationary and movable blades 159 and 161 coact to cut off the wedge4' from the hoop 4". Next the rod 157 is reciprocated so that its pusher156 pushes the wedge 4' into the groove 168 of the magazine 169.Thereafter the rod 175 is reciprocated as the cam plate 170 rotates sothat the catch 173 is reciprocated and consequently the ratchet wheel167 and hence the magazine 169 are caused to rotate through apredetermined angle as described above. These steps are repeated untilthe wedges 4' are loaded into all the grooves 168 of the magazine 169.

Conductor Handling Means H, FIG. 11

Next referring to FIG. 11, the construction of the conductor handlingmeans H will be described in detail. The handling means are mounted onrespective brackets 17, 17' and 17", but they are substantially similarin both construction and mode of operation so that it will suffice todescribe only one handling means H mounted on the frame 17. A cylinder196 which is mounted on the frame 17 with a bracket 195 has its pistonrod attached to an L-shaped first movable base 198. One end of a guiderod 197, extended through the bracket 195 in parallel with the pistonrod, is securely attached also to the L-shaped first movable base 198. Acylinder 199 is vertically mounted on the first movable base 198 and hasits piston rod securely attached to an L-shaped second movable base 201.One end of a guide rod 200, extended through the first movable base 198in parallel with the piston rod of the cylinder 199, is securely joinedto the second base 201. A pair of clamping members or pawls 203,rotatably mounted on the second movable base 201, are adapted to beopened and closed by a cylinder 202 also mounted on the second movablebase 201. A roller 203' with an annular or circumferential conductorguide groove is rotatably carried by one of the clamping members orpawls 203 on the outer side thereof. A stationary blade 204 is securelymounted on the bracket 17 with a shaft or pin which rotatably carries amovable blade 205. A cylinder 206, mounted on the frame 17, isoperatively connected to the movable blade 205 so that the stationaryand movable blades 204 and 205 coact to cut off the conductor 3.

The mode of operation of the handling means H is as follows. When theflier 73 starts winding, the cylinders 196 and 199 are actuated so as tocause the clamping members or pawls 203 to align with the conductor 3extending from the lower end of the flier 73. Thereafter the cylinder202 is actuated so as to cause the clamping members or pawls 203 toclamp the conductor 3 therebetween. Next the cylinders 196 and 199 areso actuated that the starting end of the conductor 3 may be insertedinto the retainer or holder 47 of the coil winding head B.

After the coil 4 has been formed, the conductor 3, extended between thelower end of the flier 73 and the coil 4, is wrapped partly around theguide roller 203'. Thereafter the conductor 3 is further drawn from theflier 73 and inserted into the retainer or holder 47 and then betweenthe stationary and movable blades 204 and 205. The cylinder 206 is thenactuated so as to cut off the conductor 3.

General Mode of Operation

When the motor 13 is rotated, the turntable 16 is turned so that thecoil winding head B is brought to the coil winding position immediatelybelow the winding means D. Next the cylinder 59 of the drive or indexmeans C is actuated, whereby the pins 57 are inserted into the bushings50 and the cylinder 61 is actuated, whereby the coil winding head B isindexed in the manner described elsewhere (See FIG. 5). Thereafter thecylinders 59 and 61 are disabled, but the cylinders 196 and 199 of thehandling means H (See FIG. 11) are activated so that the clampingmembers or pawls 203 are aligned with the conductor 3 drawn from thelower end of the flier 73 and then clamp it, thereby drawing it furtherand inserting it into the retainer 47 so as to form the starting end ofthe coil. Next the motors 81 and 84 of the winding means D (See FIG. 6)are driven in synchronism with each other so as to cause the flier 73 towind the coil 4 around a predetermined bobbin which is formed by themain blades 28 and the first auxiliary plate 35. While the flier 73 isturning, it is gradually vertically reciprocated so as to provide aedgewise wound coil 4. When a first few turns are wound, the cylinder202 (See FIG. 11) is actuated to cause the clamping members or pawls 203to open, thereby releasing the conductor 3. When the coil 4 for thefirst pole is formed, both the motors 81 and 84 are stopped. In thiscase, the flier 73 is returned to its initial position after having madea few vertical strokes.

Next the cylinder 59 of the drive or index means C (See FIG. 5) isactuated again, thereby rotating the coil winding head B through 90° andboth the cylinders 59 and 61 are returned to their initial states. Thenthe motors 81 and 84 of the winding means D are driven again so that thecoil 4 for the second pole is formed around a bobbin formed by the mainblades 28 and the auxiliary plate 35. In this case, the motor 81 isdriven in the direction opposite to the direction for winding the firstcoil 4. The crossover lead 4a between the first and second poles isextended the shortest distance between both poles. In like manner, fourcoils 4 for one phase are continuously formed. After the four coils 4have been formed, the cylinders 196 and 199 of the handling means H (SeeFIG. 11) are actuated in such a way that the roller 203' carried by oneof the clamping members or pawls 203 may be aligned with the conductor 3extending between the flier 73 and the coil and then receive theconductor 3. The conductor 3 is drawn from the flier 73 and insertedinto the retainer 47, whereby the finishing end or lead may be provided.Thereafter the conductor 3 is cut off by the stationary and movableblades 204 and 205 by actuating the cylinder 206.

After the four coils 4 for the first phase are completed in the mannerdescribed above, the motor 13 (See FIG. 1) is driven again so as torotate the turntable 16 through 90°, thereby bringing the coil windinghead B to the next winding position immediately below the winding meansD'. The coils for the second phase are formed in a manner substantiallysimilar to that described above. However it should be noted that thecylinder 47' on the frame 17' (See FIG. 3) is actuated so as to shiftthe auxiliary plate 41 toward the blade guide 23 or the main blades 28,whereby a bobbin may be formed by the main blades 28 and the auxiliaryplate 41.

The coil winding head B carrying all the coils to be inserted into thestator core 7 is brought to the insertion position between the holdingmeans E and the insertion means F (See FIG. 1). The pallet 104 with thestator core 7 is mounted on the holding means E (See FIG. 7) and thecylinders 107 and 112 thereof are actuated in such a way that thecylindrical projection 109 may be spaced apart from the stator core 7 bya predetermined distance while the tubular projection 113 may beinserted into the stator core 7, whereby the latter may be accuratelypositioned. Next the motor 136 of the insertion means (See FIGS. 1 and8) is driven in one direction and then the electromagnetic clutches 137,138 and 139 are energized or engaged. Then the lift plate 129 and theinsertion plate 134 and the movable base 147 of the wedge supply means G(See FIGS. 9 and 10) are lifted so that the upper plate 166 of the wedgesupply means G pushes upwards the lower holder 30 of the coil windinghead B until the lower holder 30 engages with the upper holder 27 (SeeFIG. 3). As a result, the auxiliary blades 31 are lifted to the sameheight as the main blades 28, whereby the insertion tooling is formed asdescribed in detail elsewhere. Then the electromagnetic clutches 137 and139 are de-energized or disengaged so that only the insertion plate 134is further raised. Concurrently the cylinders 141 (See FIG. 8) areactuated to push upwards the pins 45 of the coil winding head B, therebypushing upwards the ring-shaped holder 43. Then both the first andsecond auxiliary plates 35 and 41 are swung under the forces of the biassprings 34 and 40 in the manner described elsewhere so that the removalof the coils 4 from the bobbins may be facilitated. As the insertionplate 134 is further lifted, the wedge guide blades 133 are insertedinto the axial grooves 168 of the magazine of the wedge supply means G(See FIG. 9), thereby pushing the wedges 4' in the axial grooves 168into the wedge guides 26 and 29 (See FIG. 4). Thereafter theelectromagnetic clutch 137 is energized or engaged again so that thelift plate 129 is lifted in unison with the insertion plate 134. As aconsequence, the shaft 128 (See FIG. 8) pushes upwards the lower holder30, whereby the insertion tooling (the main and auxiliary blades) isinserted into the stator core 7. When the upper end of the insertiontooling is extended slightly above the upper surface of the stator core7, the electromagnetic clutch 137 is de-energized or disengaged so thatthe further lift of the lift plate 129 is stopped. The insertion plate134 continues to rise so that the shaft 132 (See FIG. 8 again) pushesupwards the insertion block 46 (See FIG. 3) which, in turn, pushes thecoils 4 held between the main and auxiliary blades 28 and 31 upwardlyinto the slots of the stator core 7. The blades 133 push the wedgesupwardly through the wedge guides 26 and 29 into the slots of the statorcore 7. In this case, the leads of the coils 4 are released from theretainers or holders 47. The upward movement of the stator core 7 due tothe forces applied thereto when the coils 4 are inserted may beprevented by the cylindrical projection 109 (See FIG. 7). As theinsertion block 46 is pushed into the stator core 7, the tubularprojection 113 of the holding means E (See FIG. 7 again) is withdrawnfrom the core 7.

After the coils 4 and the wedges 4' have been completely inserted intothe slots of the stator core 7 in the manner described above, the motor135 of the insertion means (See FIG. 1) is reversed in direction so thatthe insertion plate 134 is lowered along with the shaft 132 and thewedge guide blades 133 (See FIG. 8). Next the electromagnetic clutch 137is energized or engaged again so that the lift plate 129 is loweredalong with the shaft 128. Concurrently the cylinder 116 of the holdingmeans E (See FIG. 7) is actuated to extend the rod 116, thereby pushingthe insertion block 46 downwards away from the stator core 7. Then theinsertion block 46 pushes both the upper and lower holders 27 and 30downwards so that both the main and auxiliary blades 28 and 31 arepulled out of the stator core 7. Next the electromagnetic clutch 139 isenergized or engaged to lower the wedge supply means G. When all thewedge supply means G, the lift plate 129 and the insertion plate 134 arelowered to their initial positions, the electromagnetic clutches 137,138 and 139 are de-energized or disengaged and then the motor 135 isstopped.

The main and auxiliary blades 28 and 31 are lowered until theprojections 26' and 29' engage with the projections 24 and 22,respectively, so that the coil winding head B is ready for the next coilwinding (See FIG. 3).

The cylinders 107, 112 and 116 of the holding means E (See FIG. 7) areactuated so that the holding plate 110, the movable base 114 and the rod115 are all lifted. Thereafter the pallet 104 with the stator core 7with the inserted coils 4 and wedges 4' is removed and a new pallet 104with an empty stator core 7 is placed on the supporting plate 106.Meanwhile the motor 152 of the wedge supply means G (See FIGS. 9 and 10)is driven in order to insert new wedges 4' into the axial grooves 168 ofthe magazine 169.

In summary, according to the present invention, the coils 4 for onephase may be continously formed without cutting off the coils 4 for eachpole. In addition, all the coils 4 and wedges 4' may be inserted intothe slots of the stator core 7 by one insertion step.

What is claimed is:
 1. A machine for winding and inserting coils of the type wherein a flier is rotated so as to wind the conductor drawn from the flier around two blades of an insertion tooling and an auxiliary plate located radially outwardly of said two blades and spaced apart therefrom by a predetermined distance, thereby forming a coil which is directly inserted into a magnetic core of a rotary electric machine, said machine CHARACTERIZED by the provision of a plurality of coil winding heads each having an insertion tooling with wedge guides, the blades of said insertion tooling being divided into alternating main and auxiliary blades which are spaced apart from each other at a predetermined distance, said auxiliary blades being so arranged as to be movable relative to said main blades, said auxiliary blades being retracted from said main blades when a coil is wound around a bobbin formed by two main blades and one auxiliary plate, said auxiliary blades being to align with said main blades when the coils are inserted into said magnetic core; anda drive or index means provided for each of said coil winding heads for intermittently rotating said coil winding head through a predetermined angle for indexing.
 2. A machine for winding and inserting coils of the type wherein a flier is rotated so as to wind the conductor drawn from the flier around two blades of an insertion tooling and an auxiliary plate located radially outwardly of said two blades and spaced apart therefrom by a predetermined distance, thereby forming a coil which is directly inserted into a magnetic core of a rotary electric machine, said machine CHARACTERIZED by the provision of a plurality of coil winding heads each having an insertion tooling with wedge guides, the blades of said insertion tooling being divided into alternating main and auxiliary blades which are spaced apart from each other at a predetermined distance, said auxiliary blades being so arranged as to be movable relative to said main blades, said auxiliary blades being retracted from said main blades when a coil is wound around a bobbin formed by two main blades and one auxiliary plate, said auxiliary blades being raised such that the upper ends of all the blades are made of uniform height, when the coils are inserted into said magnetic core;a drive or index means provided for each of said coil winding heads for intermittently rotating said coil winding head through a predetermined angle for indexing, said drive means being selectively engageable with and disengageable from said coil winding head; a holding means for positioning and holding said magnetic core at the insertion position in opposed relationship with the coil winding head brought to said insertion position; a wedge supply means having a wedge magazine disposed in opposed relationship with said holding means with said coil winding head brought to said insertion position being interposed therebetween, said wedge magazine having a plurality of equiangularly spaced axial grooves formed in the outer cylindrical surface thereof for receiving therein wedges; and an insertion means disposed at said insertion position and provided with a shaft means extendable through said wedge magazine and said coil winding head brought to said insertion position for inserting the coils into the slots of said magnetic core and with a plurality of wedge guide blades extendable through said axial grooves of said wedge magazine, thereby inserting the wedges into the slots of said magnetic core.
 3. A machine for winding and inserting coils of the type wherein a flier is rotated so as to wind the conductor drawn from the flier around two blades of an insertion tooling and an auxiliary plate located radially outwardly of said two blades and spaced apart therefrom by a predetermined distance, thereby forming a coil which is directly inserted into a magnetic core of a rotary electric machine, said machine characterized by the provision of a transfer means including an index turntable;a plurality of coil winding heads rotatably mounted on said index turntable and equiangularly spaced apart from each other, each of said coil winding heads including a base rotatably mounted on said index turntable, a plurality of main blades each having a wedge guide extended from said base and equiangularly spaced apart from each other, and a plurality of auxiliary blades each having a wedge guide extended from said base, disposed alternately of said main blades along the same circle of said main blades and equiangularly spaced apart from each other, said auxiliary blades being movable relative to said main blades axially thereof in such a way that when a coil is wound, said auxiliary blades may be retracted so that the coil may be wound around a bobbin formed by two main blades and one auxiliary plate, but when the coils are to be inserted into the slots of said magnetic core, said auxiliary blades are raised such that the upper ends of all the blades are made of uniform height, thereby forming an insertion tooling; a plurality of winding means the number of which is at least one less than the number of said coil winding heads, said winding means being disposed in opposed relationship with and upwardly of said coil winding heads rotated by said turntable, respectively, except one, each of said winding means having a flier carried by a winding shaft for winding the conductor around said bobbin, thereby forming a coil; a plurality of drive or index means equal in number to said coil winding heads and disposed in opposed relationship with and downwardly of said winding means, respectively, with said coil winding heads being interposed therebetween, said drive or index means being selectively engageable with and disengageable from the corresponding coil winding head so as to rotate the latter through a predetermined angle, thereby indexing the angular coil winding position thereof; a holding means disposed immediately above the insertion position to which is brought the coil winding head carrying all the coils ready to be inserted into the slots of said magnetic core, said holding means being adapted to securely hold said magnetic core in position; a wedge supply means disposed below said insertion position and including a wedge magazine which is vertically movable toward and away from said coil winding head brought to said insertion position and coaxially of said magnetic core held by said holding means, said wedge magazine having a plurality of equiangularly spaced apart, axial grooves formed in the outer cylindrical surface thereof for recieving therein wedges, respectively; and an insertion means disposed immediately below said insertion position, said insertion means including a shaft which is vertically extendable through said wedge magazine of said wedge supply means and said coil winding head brought to said insertion position, thereby inserting the coils carried on said coil winding head into the slots of said magnetic core held by said holding means, said insertion means further including a plurality of equiangularly spaced apart wedge blades which are vertically extendable into said axial grooves, respectively, of said wedge magazine, thereby pushing the wedges into the slots of said magnetic core held by said holding means.
 4. A machine for winding and inserting coils as set forth in claim 1, 2 or 3 wherein the wedge guides and the associated blades, which form said insertion tooling, are coupled together for slidingly moving relative to each other with elastic means interposed therebetween, respectively, whereby even after said wedge guides engage with said magnetic core held by said holding means, said blades may be further inserted into said magnetic core. 